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SRSB EM Best Practice Guide Pump 2009 PDF
SRSB EM Best Practice Guide Pump 2009 PDF
Energy Efficiency
Best Practice Guide
Pumping Systems
Contents
Introduction
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
8
8
10
13
14
14
19
20
20
21
5
5.1
5.2
5.3
5.4
5.5
23
24
24
24
25
29
30
32
Appendix A
Appendix B
Glossary
33
37
Table of Contents
List of Figures
Figure 1:
Figure 2:
Figure 3:
Figure 4:
Figure 5:
Figure 6:
Figure 7:
Figure 8:
Figure 9:
Figure 10:
Figure 11:
Figure 12:
Typical proportions in the life cycle cost analysis for a medium-sized industrial pump.
Example of details recorded for a piping system configuration.
Calculating pumping system efficiency.
Centrifugal pump performance curves.
Performance curves for different impellor sizes.
Multiple-speed pump characteristic curves.
Multiple-pump operation.
Average wear trends for maintained and unmaintained pumps.
A simple pumping configuration diagram.
Centrifugal pump types and ranges.
A simplified centrifugal pump characteristic curve.
The duty point of a pump.
5
10
12
16
17
18
18
20
24
25
27
27
List of Tables
Table 1:
Table 2:
Table 3:
Table 4:
Table 5:
Table 6:
Energy costs for various electricity costs in a fully loaded 100 kW motor.
Common pumping problems and measures to improve efficiency
Techniques to lower pump energy consumption.
Indications that a pump is oversized.
Pumping efficiency guide.
Design considerations for efficient pumping systems.
Table of Contents
6
9
13
15
26
29
1 Introduction
Introduction
Initial costs
Energy costs
Maintenance
costs
Other costs
Table 1: Energy costs for various electricity costs in a fully loaded 100 kW motor. 4
Operating Time Electricity Costs in a Fully Loaded 100 kW Motor
8 c/kW
10 c/kW
12 c/kW
14 c/kW
1 hour
$9
$11
$13
$16
24 hours
$213
$267
$320
$373
1 month
$6493
$8117
$9740
$11,363
1 year
$77,920
$97,400
$116,880
$136,360
Step 1
Assess &
analyse your
existing system
Step 2
Prioritise
opportunities
Step 3
Reduce
unnecessary
demand
Step 4
Review your
pump
Step 5
Review flow
rate controls
Step 6
Optimise piping
configurations
Step 7
Review your
motor
Unnecessary demand
on pumping system
Oversized pumps
Pump wear
Pump maintenance
Change impeller
Oversized motor
Change motor
Inefficient motor
Install monitoring
Conduct a survey
10
11
Grid
Station
transformer
Recirc line
MCC
Pump
Motor
12
Savings
1060%
540%
1030%
13%
12%
13
14
Description
Excessive flow noise Oversized pumps cause flow-induced pipe vibrations, resulting in excessive noise
and increased damage to pipework (including flanged connections, welds and
piping supports)
Highly throttled flow Pumps tend to remain in more restrictive positions in systems with oversized pumps;
control valves
this increases backpressure, further decreasing efficiency
Frequent replacement Increased backpressures from increased flow rates creates high radial and thrust
of bearings and seals
bearing loads as well as high pressures on packing glands and mechanical seals
Heavy use of bypass lines A system that heavily uses bypass lines indicates that the system has either
oversized pumps, is not balancing properly, or both
Intermittent pump operation Pumps being used for purposes such as filling or emptying tanks that run very
intermittently indicate oversizing and hence suffer increased start/stop inefficiencies
and wear, as well asincreased piping friction
15
When operating a pump at flow rates higher than the BEP (that is, to the
right of the dotted line), the effects are low efficiency, increased power
needs, noise and vibration, giving reduced life due to increased radial
loads on bearings.
The likely effects of a pump operating at flow rates lower than the BEP
(that is, to the left of the dotted line) are low efficiency, noise and vibration,
giving reduced life due to increased radial loads on bearings and temperature
rise due to dissipated energy created by low efficiency. Some of the
common measures to rectify this are to use a smaller pump, a smaller
multi-stage pump or to install bypass piping.
Increased power,
lower efficiency,
noise, vibration
Temp rise,
lower efficiency,
noise, vibration
60
54
Performance curve
48
42
BEP
Head 36
(m)
30
Efficiency (%)
Efficiency
70
60
50
24
40
18
30
12
bhp
20
6
0
12
10
0
6.3
12.6
bhp
(kW)
3
0
18.9
Flow (L/s)
16
78%
180
160
76%
74%
140
Head
(ft)
Iso-efficiency lines
200
120
100
Head/flow curves
80
60
40
20
0
0
50
100
150
200
250
Flow (gpm)
17
200
180
System curve
High speed
160
Head
(ft)
140
120
Medium speed
100
80
60
Pump curves
Low speed
40
20
0
0
50
100
150
200
250
Flow (gpm)
180
160
140
Head
(ft)
Pump curves
120
System curve
100
80
60
40
20
0
0
50
100
150
200
250
Flow (gpm)
18
19
Original efficiency
Restored efficiency
1012.5%
Maintained
Unmaintained
Efficiency
Replacement
pump needed
New
10 years
Time in service
20
21
22
5 Solution 2 Design
a new system
A good pumping system design will consider all the
elements of a pumping system, including how to
minimise the need for pumping in the first place.
Many of the principles outlined in Solution 1 can be used
in designing a new system. However, with a completely
new set of components, there is greater potential for
optimal design.
A suggested process to follow when designing a new
pumping system is as follows:
Step 1
Assess production
requirements &
minimise needs
Step 2
Design with
whole-systems
approach
Step 3
Design efficient
pump stations
Step 4
Select efficient
pumping
components
Step 5
Improve your
design
23
24
25
Centrifugal
20
10
Mixed flow
5
3
Axial flow
2
1
0.1 0.2 0.3 0.5 1
Capaciy (m/min)
26
End Suction
(Incl. vertical &
close impeller
types) (%)
100
Vertical
Multistage
& Horizontal
Multistage/Close
Coupled (close
impeller types)
(%)
Submersible
(semi open and
open impeller
types (%)
Processor Pump
(open impeller
types)
(%)
50 - 60 -
55 - 75
48 - 55
48 - 52
110 - 250
65 - 75
73 - 76
68 - 75
48 - 55
48 - 52
300 - 450
75 - 80
75 - 79
70 - 75
55 - 65
48 - 52
460 - 600
78 - 82
75 - 79
55 - 65
48 - 52
700 - 1000
80 - 85
78 - 82
65 - 72
48 - 52
1100 - 1500
83 - 87
78 - 82
60 - 68
1600 - 2500
83 - 88
78 - 83
60 - 70
2600 - 3600
80 - 86
70 - 75
3700 - 4000
82 - 86
75 - 80
>5000
80 - 88
75 - 80
Horizontal
/ Vertical
split casing
(centrifugal and
close impeller
types) (%)
27
Head
Power
Pump curve
System
curve
Efficiency
NPSH R
Duty point
Head
Flow
Static
head
Rate of flow
0
3
28
29
Design Considerations
System
considerations
Pump stations
Piping system
configuration
Throttling controls
30
Component
Design Considerations
Operations and
maintenance
Service
providers
31
32
Appendix A Glossary
Term
Meaning
adjustable speed
drives (ASDs)
backpressure
Appendix A Glossary
33
Term
Meaning
heat exchanger
Appendix A Glossary
34
Term
Meaning
Appendix A Glossary
35
Term
Meaning
specific gravity The ratio of the density of a fluid to the density of water
at standard conditions
static head The head of water a pump must overcome before it will
produce any flow; it is a result of the height difference
between the suction water level and delivery water level
throttling Used to impose a restriction in a pumping system, often
by means of a valve to control the flow through the system
total head A measure of the total energy imparted to the fluid by a
centrifugal pump, which includes static pressure
increase and velocity head
valve A device used to control fluid flow in a piping system
there are many types of valves with different flow control
characteristics, sealing effectiveness and reliability
vapour pressure The force per unit area that the fluid exerts in an effort
to change the phase from a liquid to a vapour; it is a
function of a fluids chemical and physical properties,
and its temperature
variable-speed drive (VSD) A way of controlling the speed of a motor, usually
electronically using an inverter; the speed can be varied
manually, but is more often controlled via a signal from
the process, for example, pressure, flow or level
viscosity The resistance of a fluid to flow when subjected to
shear stress
Appendix A Glossary
36
Appendix B
FurtherReading / References
Motor Solution Online System Optimisation Guide
Optimising pump and fan applications, Australian
Greenhouse Office, March 2006.
www.greenhouse.gov.au/motors
Pump System Assessment Tool (PSAT), US
Department of Energy Energy Efficiency and
Renewable Energy.
www1.eere.energy.gov./industry/bestpractices/motors.
html
Variable Speed Driven Pumps Best Practice Guide,
British Pump Manufacturers Association,
Gambica Association.
Variable Speed Pumping; A guide to successful
applications, Executive Summary, US Department
ofEnergy Energy Efficiency and Renewable Energy,
Hydraulic Institute and Europump, May 2004.
www1.eere.energy.gov./industry/bestpractices/motors.
html
37
References
1
10
11
12
13
14
38
Acknowledgments
Sustainability Victoria would like to acknowledge
Climate Managers for preparing this report and
Flowserve Pty Ltd for their review of this guide.